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8/3/2019 Epa+608+Technician+Training+Show 1

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DESIGN AIRIn cooperation with

The Esco Institute

presents . . .

Click the mouse orPage Up orPageDown key to advance through the program.

Click this button to exit the program . . . or Enter to keep going!


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EPA CERTIFICATION

TRAINING

for

AirConditioning& Refrigeration Technicians

Federal Clean Air Act - 608


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This presentation is designed to help technicians

prepare for the EPA 608 Certification Exam.

This exam is offered regularly by DESIGN AIR

UNIVERSITY at locations throughout Wisconsin

and Michigan's U.P.

You must pre-register for this exam.

When you pre-register, you will receive a study

guide that will help you prepare for the exam. To receive information about the date & site of

the next exam in your area as well as the exam fee,

call 800-569-3389 and ask for Mike Mills.


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Section 608 of the Federal Clean Air Act

REQUIRES

All persons who maintain, service, repair, or dispose

of appliances that contain regulated refrigerants, be

certified in proper refrigerant handling techniques.

If EPA regulations change after a technician becomes

certified, it is the responsibility of the technician to

comply with any future changes.


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There are Four (4) Categories of

Technician Certification


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TYPEI

Persons who maintain, service or repair

small appliances must be certified asType I technicians.


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TYPEII

Persons, who maintain, service, repair

or dispose of high or very high-pressureappliances, except small appliances and

motor vehicle air conditioning systems,

must be certified as Type II technicians.


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TYPEIII

Persons, who maintain, service, repair,

or dispose of low-pressure appliances

must be certified as Type III technicians.


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UNIVERSAL

Persons, who maintain, service or repairboth low and high-pressure equipment, as

well as small appliances, must be certified

as Universal technicians.


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TESTFORMAT

The test contains four sections, Core (A), I, II, III.

Each section contains twenty five (25) multiple-choice

questions.

A technician MUST achieve a minimum passing score of70 percent on the CORE and in each group in which they

are to be certified. ie: 18 out of 25 questions in each

section.

If a technician fails one or more of the Sections on the

first try, they may retake the failed Section(s) without

retaking the Section(s) on which they earned a passing

score. In the meantime the technician will be certified in

the Type for which they received a passing score.


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Choose thesection you want tostudy.

Core click here:

Type I click here:

Type II click here:

Type III click here:


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WHATISREFRIGERATION

Heat is a form of energy. Refrigeration is

the movement of heat from an area where itis not wanted to an area where it is less

objectionable. For example, a refrigerator

removes heat from the inside of the cabinet

and transfers it to the outside.


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GAUGEMANIFOLDSET

One of the most important tools to the HVAC&R

technician is the gauge manifold set. The compound

gauge (BL

UE) and the high pressure gauge (RED)are connected to the manifold, and the manifold is

then connected by hoses to access ports to measure

system pressures. The compound gauge measures

low pressure (psig) and vacuum (inches Hg.). The

high pressure gauge measures high side (discharge)

pressure. The manifold is also equipped with a center

port, (usually a YELLOW hose), that can be

connected to a recovery device, evacuation vacuum

pump, or charging device. EPA regulations require

that hoses be equipped with low loss fittings that will

minimize refrigerant loss when hoses are

disconnected.


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PRESSURE/VACUUM

Pressure is defined as the force per

unit area, most often described as

pounds per square inch (U.S.).


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ATMOSPERIC PRESSURE

Our atmosphere extends about 50 miles above the earth

and consists of approximately 78% nitrogen, 21% oxygen,

the remaining 1% is composed of other gasses. Eventhough the gas molecules are very small, they have weight.

The atmosphere exerts a pressure of 14.7 lbs. per square

inch at sea level. At higher altitudes, the atmospheric

pressure will be significantly less.


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The most common method of measuring

atmospheric pressure is the mercury

barometer. Normal atmospheric pressure at sea

level (14.7 psia) will support a column of

mercury 29.92 inches high.

Mercury barometer

Atmospheric pressure

will support a column of

mercury 29.92 inches in

the sealed tube.


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GAUGEPRESSURE

The pressure reading we most often use

is called gauge pressure. Atmosphericpressure is shown as 0 psi or psig

(pound per square inchgauge).


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Compound gauges that are

used to measure low side

pressures in air conditioningsystems can measure

pressures both above and

below 0 psig. Gauge readings

are relative to atmosphericpressure. It will be necessary

to adjust a compound gauge

periodically to compensate

for changes in atmospheric

pressure.

COMPOUND GAUGES


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VACUUM

Pressures below atmospheric are usually read in inches of

mercury (in. Hg) or in millimeters of mercury (mm Hg).

A thorough understanding of vacuum principles is an

absolute necessity for the air conditioning technician.

Since an increase in pressure will increase the boiling

point of a liquid, the opposite is also true. Lower pressure

will result in a lower boiling point. Any pressure below

atmospheric is considered a partial vacuum. A perfect

vacuum would be the removal of all atmospheric pressure.

For reading deep vacuum, a micron gauge is used. A

micron is 1/1000th of a millimeter.


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ABSOLUTEPRESSURE

The absolute pressure scale allows measurement of

both vacuum and pressure to be made using the same

units. Absolute pressure measurements are indicated as

psia (pounds per square inch absolute). 0 psia is a

pressure that cannot be further reduced.

Since atmospheric pressure will measure 14.7 psia atsea level, gauge pressure can be converted to absolute

pressure by adding 14.7 to the gauge pressure reading.


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CORE

SECTIONAGeneral Knowledge

Passing the CORE is a prerequisite

to achieving certification


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STRATOSPHERICOZONE

DEPLETION

The stratosphere is the Earth's security blanket. It is

located between 10 and 30 miles above sea level and iscomprised of, among other things, Ozone.

An Ozone molecule consists of three oxygen atoms (03).


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2=21(3527(&7686)520+$50)8/8/75$ 9,2/(7

5$',$7,21$1'+(/36720$,17$,167$%/(($57+

7(03(5$785(6

StratosphericOzone Depletion is a

GLOBAL PROBLEM


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DepletionofOzone in the

Stratosphere Causes . . .

Crop Loss

Increase In Eye Diseases

Skin Cancer

Reduced Marine Life

Deforestation

Increased Ground Level Ozone


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CFCs & HCFCs

in theSTRATOSPHERE

CFC's and HCFC's, when released into the atmosphere

deplete the Ozone layer.

The chlorine in these compounds is the culprit.When a chlorine atom meets with an Ozone molecule, it

takes one Oxygen atom from the Ozone. This forms a

compound called Chlorine Monoxide (ClO) and leaves an

O2molecule.


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CHLORINEISTHECULPRIT

Chlorine Monoxide will collide withanotherOzone molecule, release its Oxygenatom, forming two O

2molecules, and leave

the chlorine free to attack anotherOzone

molecule.

A single Chlorine atom can destroy100,000 Ozone molecules!!!


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SOURCEof CHLORINE

in the

STRATOSPHERE

Some believe that the Chlorine found in the stratosphere comes

from natural sources such as volcanic eruptions. However, air

samples taken over erupting volcanoes show that volcanoes

contribute only a small quantity of Chlorine as compared to CFC's.

In addition, the rise in the amount of Chlorine measured in thestratosphere over the past two decades matches the rise in the

amount of Fluorine, which has different natural sources than

Chlorine, over the same period. Also, the rise in the amount of

Chlorine measured in the stratosphere over the past twenty years,

matches the rise in CFC emissions over the same period.


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Chlorine in CFCs

vs.Naturally Occurring Chlorine

The chlorine in CFC's will neither dissolve inwater nor break down into compounds that dissolve

in water, so they do not rain out of theatmosphere and return to earth.

Naturally occurring chlorine will dissolve in water

(humidity) and rain out of the atmosphere.


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OZONEDEPLETIONPOTENTIAL

Ozone Depletion Potential (ODP) is a

measurement of CFC's and HCFC's ability todestroy ozone. CFC's have the highest ODP.

HFC's (R-134A) do not contain chlorine and

have no Ozone Depletion Potential.


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The Three (3) Primary Types

of

REFRIGERANTS

TYPE EXAMPLE ELEMENTS

CFC R-11 R-12 R-500 Chlorine-Fluorine-Carbon

HCFC R-22 R-123 Hydrogen-Chlorine-Fluorine-Carbon

HFC R-134a R-410A Hydrogen-Fluorine-Carbon


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THREE PRIMARY REFRIGERANT TYPES:

CFC = CHLORINE - FLUORINE - CARBON

EXAMPLE: R-11, R-12, R-500

HCFC = HYDROGEN - CHLORINE - FLUORINE - CARBON

EXAMPLE: R-22, R-123

HFC = HYDROGEN - FLUORINE - CARBON

EXAMPLE: R-134a


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CLEANAIR ACT

The United States Environmental Protection Agency (EPA) regulates

section 608 of the Federal Clean Air Act. Failure to comply could

cost you and your company as much as $27,500. per day, per violationand there is a bounty of up to $10,000 to lure your competitors,

customers and fellow workers to turn you in. Service technicians who

violate Clean Air Act provisions may be fined, lose their certification,

and may be required to appear in Federal court.


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It isa Violationof

Section 608 to:

Falsify or fail to keep required records;

Fail to reach required evacuation rates prior to openingor disposing of appliances;

Knowingly release (vent) CFC's, HCFC's or HFCswhile repairing appliances, with the exception of de-minimus releases;

Knowingly release (vent) CFC's, HCFC's or HFCswhile repairing appliances, with the exception of de-minimus releases;

Vent CFC's or HCFC's since July 1, 1992; continued . . .


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It isa Violationof

Section 608 to:

Vent HFC's since November 15, 1995;

Fail to recover CFC's, HCFC's or HFCs before opening ordisposing of an appliance;

Fail to have an EPA approved recovery device, equippedwith low loss fittings, and register the device with the EPA;

Add nitrogen to a fully charged system, for the purpose ofleak detection, and thereby cause a release of the mixture;

Dispose of a disposable cylinder without first recovering anyremaining refrigerant (to 0 psig.) and then rendering the

cylinder useless, then recycling the metal;


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STATE& LOCALREGULATIONS

State & local governments may not pass regulations

that are less strict than those contained in Section 608.They may pass regulations that are as strict or stricter

than Federal regulations.


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THEMONTREAL PROTOCOL

The Montreal Protocol is an internationaltreaty.

It regulates the production and use of CFCs,HCFCs, halons, methyl chloroform and carbontetrachloride.

CFC's were phased out of production on

December 31, 1995. HCFC refrigerants arescheduled of phase out in the future.

When virgin supplies of CFC's are depleted, futuresupplies will come from recovered, recycled, or

reclaimed refrigerants.


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RECOVERY

To remove refrigerant in any

condition from an applianceand store it in an

EXTERNAL CONTAINER


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RECOVERY& REUSE

Refrigerant that has been recovered from a unit

(if it is not contaminated) may be reused in the

unit from which it was removed.

It may be reused in another unit so long as the equipment

that it was removed from and the unit to which it is being

introduced is owned by the same owner. This requirement

is designed to prevent excessive cross-contamination.


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RECYCLE

To clean refrigerant for reuse by

separating the oil from the refrigerant

and removing moisture by passing it

through one or more filter driers


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RECLAIM

To process refrigerant to a level equal to

new product standards as determined by

chemical analysis. Reclaimed refrigerantmust meet standards set forth in ARI 700

before it can be resold.


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RECOVERYDEVICESRefrigerantRecovery and/orRecycling equipment manufactured

afterNovember 15, 1993, must be certified and labeled by an

EPA approved equipment testing organization to meetEPA

standards. There are two basic types of recovery devices.

1) System-dependentwhich captures refrigerant with theassistance of components in the appliance from which

refrigerant is being recovered.

2) "Self-contained which has its own means to draw therefrigerant out of the appliance (a compressor).


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SALESRESTRICTION

As of November 14, 1994, the sale of CFC and

HCFC refrigerants was restricted to certified

technicians.

Only technicians certified under Clean Air Act Section

609 (Motor Vehicle Air Conditioning) are allowed to

purchase R-12 in containers smaller than 20 lbs.


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SUBSTITUTE

REFRIGERANTS& OILS

HFCs are considered Ozone friendly. R-134A is the leading

candidate for CFC R-12 retrofit, but it is not a drop-in

substitute. Actually, there is not a drop-in alternative, but R-

134A can be used in most R-12 systems by following

appropriate retrofit procedures.

HFCs will not mix with most refrigerant oils used with CFCs

& HCFCs. The oils used in most HFC systems are ESTERS.

Esters cannot be mixed with other oils. It is also important to

remember that when leak testing an HFC system to use

pressurized nitrogen.


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REFRIGERANTBLENDS

There are several refrigerant blends commonly in use.

Some of the blends are called Ternary, which means theyare a three-part blend. Ternary blends are used with a

synthetic alkylbenzene oil.


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REFRIGERANTBLEND

CHARGING

The components of a blended refrigerant will leakfrom a

system at uneven rates due to different vapor pressures.

Therefore, the propercharging method for blended

refrigerants is to weigh into the high side of the system as

a liquid.


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TEMPERATUREGLIDE

Temperature glide refers to a refrigerant blend that hasa range of boiling points and / or condensing points

throughout the evaporator and condenser respectively.


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AZEOTROPIC

REFRIGERANTS

An azeotropic mixture acts like a single component

refrigerant over its entire temperature / pressure range. Anazeotrope does not have a temperature glide.


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HYGROSCOPICOIL

Most refrigerant oils are hygroscopic.

A Hygroscopic oil is one that easily absorbs &releases moisture (has a high affinity for water).

An oil sample should be taken and analyzed if a system

has had a major component failure.


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RECOVERY

andCUSTOMER

RELATIONS

Some customers have complained about

the increased cost of service. To justify

the increase, simply explain that you are

duty bound and required by law to

recover refrigerants in order to protect

the environment and human health.


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EPA REQUIREMENTOF

EQUIPMENTMANUFACTURERS

EPA regulations require a service

aperture or process stub on all

appliances that use a Class I or Class II

refrigerant in order to make it easier to

recover refrigerant.


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MIXED REFRIGERANTRECOVERY

Do not mix refrigerants in a recovery cylinder.

A refrigerant mix may be impossible to reclaim.

If you discover that two or more refrigerants have beenmixed in a system, you must recover the mixture into a

separate tank.

Badly contaminated and mixed refrigerants must be destroyed.


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with a

COMPRESSOR BURN-OUT

A strong odor is an

excellent indicator of a

compressor burn-out .

If you suspect a

compressor burn-out,

flush the system &

watch for signs of

contamination in the

oil.

If nitrogen is used to

flush debris out of the

system, the nitrogen

may be vented.

A suction line filter

drier should be

installed to trap any

debris that may damage

the new compressor.


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RECOVERYSPEED

Long hoses will reduce pressure resulting in

increased recovery time.

Since all refrigerants have a pressure

temperature relationship, lower ambient

temperatures, result in slower recovery rate.


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DEH

YRATIONTo remove water and water vapor from a refrigeration system

If moisture is allowed to remain in an operating

refrigeration system, hydrochloric & hydrofluoric acids

may form.Evacuation of a system is the suggested method of

dehydration.

It is not possible to over evacuate a system.


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EVACUATION

Never evacuate a system to the air without first

following proper recovery procedures andattaining the mandated vacuum level.


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EVACUATIONESSENTIALS

forAccurate Readings & Speed

Vacuum lines should be equal to or larger than the

pump intake connection.

The piping connection to the pump should be as short alength as possible and as large in diameter as possible.

The system vacuum gauge should be connected as far as

possible from the vacuum pump.


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EVACUATION

SPEED &EFFICIENCY

FACTORS

Size of equipment being evacuated

Ambient temperatureAmount of moisture in the system

The size of the vacuum pump and suction line

Heating the refrigeration system will decrease dehydration time


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The use of a large vacuum pump could cause trapped

water to freeze.

During evacuation of systems with large amounts of

water, it may be necessary to increase pressure by

introducing nitrogen to counteract freezing.

EVACUATION

Precautions


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COMPLETING

THE

DEHYRATIONPROCESS

Measuring a system's vacuum should be done with the

system isolated and the vacuum pump turned off.

A system that will not hold a vacuum probably has a

leak.

Dehydration is complete when the vacuum gauge shows

that you have reached and held the required finished

vacuum.


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MEASURING DEHYDRATION

EFFECTIVENESS

It is impossible to determine dehydration

effectiveness using a compound gauge that

reads in inches of Hg (MERCURY)

The use of a Micron Gauge & achieving 500

microns of vacuum assures proper dehydration.


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MICRONS INCHESOF Hg Vaporization Temp of Water

at each Pressure

0 29.921 ------

20 29.92 -50100 29.92 -40

150 29.92 -33

200 29.91 -28

300 29.91 -21

500 29.90 -12

1,000 29.88 1

4,000 29.76 29

10,000 29.53 52

20,000 29.13 72

50,000 27.95 101

100,000 25.98 125

200,000 22.05 152

500,000 10.24 192

760,000 0 212


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RECOVERY CYLINDERSRecovery cylinders are designed to be refilled.

Recovery cylinders have 2 ports, one liquid and one vapor.

They must not be overfilled or heated.

Overfilling or heating can cause an explosion.NEVER heat a refrigerant cylinder with an open flame

The EPA requires that refillable refrigerant cylinders MUST

NOT BE FILLED ABOVE 80% of their capacity by weight, and

that the safe filling level can be controlled by either mechanical

float devices, electronic shut off devices (thermistors), or weight.

Refillable cylinders must be hydrostatically tested and date

stamped every 5 years.


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Refillable cylinders used for transporting recovered pressurized

refrigerant must be DOT (Department of Transportation)

approved. Approved refrigerant recovery cylinders can easily beidentified by their colors, YELLOW TOPS and GRAY BODIES.

All refrigerant recovery cylinders should be inspected for RUST. If

they show signs of rust or appear to not be secure they should be

reduced to 0 psig and discarded.


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DISPOSABLECYLINDERS

Disposable cylinders are used with

virgin refrigerant and mayNEVER be used for recovery.


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SCHRADERVALVES

It is necessary to inspect Schrader valve cores

for leaks, bends and breakage, & replace

damaged valve cores to prevent leakage.

Always cap Schrader ports to prevent

accidental depression of the valve core.


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PERSONAL SAFETY- WEAR

When handling and filling refrigerant cylinders, or

operating recovery or recycling equipment, you should

wear

SAFETY GLASSES

PROTECTIVE GLOVES

NITROGEN


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NITROGEN

PRESSURETESTINGSAFETY

When pressurizing a system with nitrogen, you should:

1. Charge through a pressure regulator

2. Insert a relief valve in the downstream line fromthe pressure regulator

3. NEVER install relief valves in series

4. Replace the relief valve if corrosion is found within

the body of a relief valve

To determine the safe pressure for leak testing, check

the data plate for the low-side test pressure value


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OXYGEN& COMPRESSED AIR

When leak checking a system, NEVERpressurize

the system with oxygen or compressed air.

When mixed with refrigerants, oxygen or

compressed air can cause an explosion.


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SAFETY & LARGE

REFRIGERANTLEAKS

If a large release of refrigerant in a confined area occurs;

S

elf ContainedB

reathing Apparatus (S

CB

A) is required.IfSCBA is not available, IMMEDIATELY VACATE AND

VENTILATE the area.

In large quantities, refrigerants can cause suffocation

because they are heavier than air and displace oxygen.

Inhaling refrigerant vapors or mist may cause heart

irregularities, unconsciousness, and oxygen deprivation

leading to death (asphyxia).


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REFRIGERANTSAFETY

&

OPENFLAMES

NEVER expose R-12 or R-22 to open flames or

glowing hot metal surfaces. At high temperatures,

R-12 and R-22 decompose to form Hydrochloric acid,Hydrofluoric acid, and Phosgene gas.

Always review the material safety data sheets, when

working with any solvents, chemicals, or refrigerants.


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SHIPPING& TRANSPORTATION

Before shipping used refrigerant cylinders, complete the

shipping paperwork include the number of cylinders of each

refrigerant, and properly label each cylinder with the type

and amount of refrigerant.

Cylinders should be transported in an upright position.

Each cylinder must have a DOT classification tag indicating

it is a 2.2 non-flammable gas.

Some states may require special shipping procedures to befollowed based on their classification of used refrigerants.

Check with the DOT in the state of origin.


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Sample Core Questions & Answers

Here are ten sample Core questions for youto practice with.

None of these are actual questions from the

Core section of the test. They do not cover all of the subject material

that you will be tested on.

T

hey do help you to practice multiplechoice type questions by reading carefully,reviewing what you have read and justrelaxing and doing your best.


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Sorry. Try again!

Click here to try again.


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Sample Core Question #1

1. The chemicals that have been identified

as contributing to ozone depletion are:

a. CFCs and HCFCs

b. CFCs and HFCs

c. HFCs and HCFCs

d. all of the above


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2. Why should technicians get EPA

certification?

a. to make more money

b. to qualify for the G.I. Bill

c. to avoid large fines

d. to attain R.S.E.S. membership


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3. Ozone depletion occurs in the . . .

a. ionosphere

b. stratosphere

c. hemisphere

d. biosphere


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4. A refrigerants Ozone Depletion

Potential (ODP) is directly related to the

presence of . . .

a. ozone molecules

b. oxygen molecules

c. fluorine atoms

d. chlorine atoms


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5. It is against the law to use a vacuum

pump on a system until first . . .

a. replacing the driers

b. following recovery procedures to

mandated levels

c. verifying the compression ratio

d. All of the above.


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6. To reclaim refrigerant one must . . .

a. Appear in a court of law

b. Process recovered refrigerant to alevel of purity equal to new refrigerant

c. Clean recovered refrigerant for reuse

by passing it through a series of driers d. Recover refrigerant from a system and

then putting it right back in the samesystem


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7. Only technicians certified under Section

609 (Motor Vehicle Air Conditioning) are

allowed to purchase refrigerants incontainers smaller than . . .

a. 16 oz.

b. 2 lbs.

c. 10 lbs.

d. 20 lbs.


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8. R-134A is a drop-in replacement for . . .

a. R-12

b. R-22

c. R-11

d. None of the above


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9. If a customer complains about the increased

costs associated with refrigerant recovery

practices, the serviceperson should . . . a. Offer them a service contract

b. Tell them to get another bid

c. Offer them a discount after checking with

your office

d. Explain that the law requires that you

follow these procedures


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10. Every five years, technicians must . . .

a. get re-certified

b. take a refresher course

c. have their recovery cylinders tested

d. pay a users fee


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Core (return) click here:

Type I click here:

Type II click here:


Click this button to exit the program . . . or keep going!


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TYPEI

Technicians servicing small appliances must be certified

in refrigerant recovery if they perform sealed system

service.

The EPA definition of a small appliance includes

products manufactured, charged, and hermetically sealed

in a factory with five pounds of refrigerant or less.

Persons handling refrigerant during maintenance, service

or repair of small appliances must be certified as either a

Type I Technician or as a Universal Technician.


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RECOVERYEQUIPMENT

MANUFACTUREDBEFORE

NOVEMBER 15, 1993

Must be capable of removing 80% of the

refrigerant, whether or not the compressor

is operating, or achieve 4 inch vacuumunder the conditions of ARI 740.


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RECOVERYEQUIPMENT

MANUFACTUREDAFTERNOVEMBER 15, 1993

Must be certified by an EPA approved testing

laboratory, (example, U.L. or E.T.L) as capable of

recovering 90% of the refrigerant if the compressoris operating, 80% of the refrigerant if the

compressor is not operating, or achieving a 4 inch

vacuum under the conditions of ARI 740.


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It's as simple as ABC


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RECOVERYEQUIPMENT

All equipment must be equipped with low loss

fittings that can be manually closed, or closeautomatically, when hoses are disconnected to

minimize the refrigerant loss.


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LEAKREPAIRREQUIREMENTS

Although leaks should be repaired

whenever possible, the EPA does notrequire leak repair for small appliances.

RECOVERY TECHNIQUES


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RECOVERYTECHNIQUESSelf-Contained (Active)

Equipment

Active recovery equipment stores refrigerant in a pressurized

recovery tank. Before operating a self-contained recovery machine,

open the tank inlet valve, and remove excessive noncondensables

(air) from the recovery tank.

An accurate pressure reading of refrigerant inside a recovery

cylinder is required to detect excessive non-condensables. The only

way to read refrigerant pressure accurately is at a stable, known

temperature. Air in a refrigeration system will cause higher

discharge pressures. Follow the operating instructions supplied by

the recovery equipment manufacturer regarding purging of non-

condensables. All refrigerant recovery equipment should be

checked for oil level and refrigerant leaks on a daily basis.

RECOVERY TECHNIQUES


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RECOVERYTECHNIQUESSystem-Dependent (Passive)

Equipment

System-dependent recovery process for small appliances

captures refrigerant into a non-pressurized container. These

are special charcoal activated plastic bag containers.

System-dependent equipment captures refrigerant with the

assistance of the appliance compressor, an external heat

source, or a vacuum pump.

A standard vacuum pump can only be used as a recovery

device in combination with a non-pressurized container

When using a system dependent recovery process on


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When using a system dependent recovery process on

an appliance with an operatingcompressor, run the

compressor and recover from the high side of thesystem. Usually, one access fitting on the high side will

be sufficient to reach the required recovery rate, as

the appliance compressor should be capable of

pushing the refrigerant to the high side.

Appliances with a non-operatingcompressor, access to

both the low and high side of the system is necessary.

In order to achieve the required recovery efficiency, it

will be necessary to take measures to help release

trapped refrigerant from the compressor oil, (heat

and tap the compressor several times and/or use a

vacuum pump).


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Because appliances with non-operating compressors

can not always achieve desired evacuation rates

utilizing system-dependent recovery equipment, the

EPA requires technicians to have at least one self-

contained recovery device available at the shop to

recover refrigerant from systems with non-operating

compressors. The exception to this rule is technicians

working on small appliances only.

System dependent devices may only be used on

appliances containing 15 lbs. of refrigerant or less.

INSTALLING PIERCING


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INSTALLING PIERCING

TYPE ACCESS FITTINGS

Fittings should be leak tested before proceeding

with recovery. It is generally recommendedthat solderless piercing type valves only be usedon copper or aluminum tubing material.

Fittings tend to leak over time and should notbe left on an appliance as a permanent serviceport. After installing a fitting, if you find thatthe system pressure is 0 psig, do not begin therecovery process.


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DEFROSTHEATERS

If the appliance is equipped with a defrost

heater, such as in a domestic frost-freerefrigerator, operating the defrost heater will

help to vaporize any trapped liquid refrigerant

and will speed the recovery process.


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DONOTRECOVER

Refrigerators built before 1950 may have used

Methyl Formate, Methyl Chloride, or SulfurDioxide as refrigerant and should not berecovered with current recovery devices.

Small appliances used in campers or otherrecreational vehicles may use refrigerants suchas Ammonia, Hydrogen, or Water, andtherefore should not be recovered usingcurrent recovery equipment.


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CHARGING CYLINDERS

When filling a graduated charging

cylinder with a regulatedrefrigerant, the refrigerant vapor

that is vented off the top of the

cylinder must be recovered.


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S l T I Q ti & A


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102

Sample Type I Questions & Answers

Here are ten sample Type I questions for you to

practice with.

None of these are actual questions from the Type Isection of the test.

They do not cover all of the subject material that

you will be tested on.

They do help you to practice multiple choice type

questions by reading carefully, reviewing what

you have read and just relaxing and doing your

best.


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103

Sample Type I Question #1

1. Type I Certification applies to . . .

a. small appliances.

b. appliances with 5lbs. or less of

refrigerant.

c. appliances charged and hermetically

sealed in a factory.



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2. All recovery equipment must be

equipped with . . .

a. temperature relief valves.

b. glycerin filled gauges.

c. low-loss hose fittings.

d. thermistors.


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105


3. The leak requirement for small appliances is . . .

a. all leaks must be repaired.

b. leaks should be repaired whenever possible.

c. leaks of one or more pounds per month must

be repaired.

d.T

here is no leak repair policy stated by the EPA.


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4. Sending a recovery cylinder to a reclamationfacility with more than one type of refrigerant in

it . . . a. saves storage space.

b. require that a contents tag be filled out.

c. may result in the cylinder being returnedunprocessed at the owners expense.

d. may lead to the technicians arrest


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5. The EPA requires technicians to . . .

a. have at least one self-contained recovery

device.

b. display a Underwriters Laboratories

(UL) label on their uniform.

c. evacuate the systems to 250 microns.

d. check for leaks 30 days after any repair.


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6. Systems using Ammonia, Hydrogen orWater should not be . . .

a. allowed to remain in service. b. recovered using current recovery

equipment.

c. compared to modern systems.

d. considered covered by the UniformDwelling Code.


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109


7. When leak checking a system use . . .

a. compressed air.

b. oxygen.

c. R-11.

d. nitrogen.


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8. When exposed to a torch flame, R-12 and R-22

will decompose to form . . .

a. hydrochloric acid.

b. hydrofluoric acid.

c. phosgene gas.

d. all of the above.


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9. The sale of CFCs and HCFCs is restricted to

a. certified technicians

b. licensed technicians

c. experienced technicians

4. trained technicians


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10. Recovery cylinders must not be filled more

than . . .

a. disposable cylinders.

b. 80% of its capacity by weight.

c. 90% of its capacity to allow for thermal.

expansion

d. 75% by volume.

Choose the section you want to study


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113


Core click here:

Type I (return) click here:

Type II click here:




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TYPE II

Technicians maintaining, servicing, repairing or

disposing of high pressure or very high-pressure

appliances, except small appliances and motor

vehicle air conditioning systems, must be certified

as a Type II Technician or a Universal Technician.


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LE AK DETECTION

After installation of a system, pressurize

the unit with nitrogen and leak check.

In order to determine the general area of

a leak use an electronic or ultrasonic leakdetector.

To pinpoint the leak use soap bubbles.


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LeakingSystems

A refrigeration unit using an open compressorthat has not been used in several months islikely to leak from the shaft seal.

During a visual inspection of any type ofsystem, traces of oil are an indicator of arefrigerant leak.

Excessive superheat, caused by a lowrefrigerant charge, is also an indication of aleak in a high-pressure system.

LEAK REPAIR


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LEAKREPAIR

REQUIREMENTSComfort Cooling

EPA regulations require that all comfort

cooling appliances (airconditioners)

containing more than 50 lbs. ofrefrigerant MUST be repaired when the

annual leak rate exceeds 15%.


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Commercial & Industrial ProcessRefrigeration

EPA regulations require that all

Commercial and Industrial Process

Refrigeration containing more than 50 lbs.of refrigerant MUST be repaired when the

annual leak rate exceeds 35%.

CommercialRefrigeration includes appliances used in

the retail food and cold storage warehouse sectors,


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the retail food and cold storage warehouse sectors,

including equipment found in supermarkets, convenience

stores, restaurants and other food establishments, andequipment used to store meat, produce, dairy products

and other perishable goods.

Industrial ProcessRefrigeration means complex

customized appliances used in the chemical,pharmaceutical, petrochemical and manufacturing

industries, including industrial ice machines and ice

rinks.


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RECOVERYEQUIPMENT

Recovery equipment must be certified by an

EPA approved laboratory (UL or ETL) to meet

or exceed ARI standards.


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RECOVERY

REQUIREMENTS

Recovered refrigerants can contain acids, moisture, and oil.

Frequently check and change both the oil and filter on a recycling

machine. Recycling and recovery equipment using hermetic

compressors have the potential to overheat when drawing a deep

vacuum because the unit relies on the flow of refrigerant throughthe compressor for cooling. Before using a recovery unit you

should always check the service valve positions, the recovery units

oil level, and evacuate and recover any remaining refrigerant

from the units receiver.

When working with multiple refrigerants, before

recovering and/or recycling a different refrigerant purge


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recovering and/or recycling a different refrigerant, purge

the recover/recycle equipment by recovering as much of

the first refrigerant as possible, change the filter, andevacuate. The only exception to this rule is for technicians

working with R-134A who must provide a special set of

hoses, gauges, vacuum pump, recovery or

recovery/recycling machine, and oil containers to be used

with R-134A only.

Recovering refrigerant in the vapor phase will minimize

the loss of oil, recovering as much as possible in the liquid

phase can reduce recovery time. The technician maychoose to speed up the recovery process by packing the

recovery cylinder in ice and/or applying heat to the

appliance. After recovering liquid refrigerant, any

remaining vapor is condensed by the recovery system.

RECOVERY


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NOTES

Refrigerant should be placed in the receiver of

units that have a receiver/storage tank.

Refrigerant should be removed from thecondenser outlet if the condenser is below thereceiver.

In a building that has an air-cooled condenseron the roof and an evaporator on the first floor,recovery should begin from the liquid lineentering the evaporator.

After recovery, refrigerant may be returned to the


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Always evacuate an empty recovery cylinder before

transferring refrigerant (recovering) to the cylinder.

y, g y

appliance from which it was removed or to another

appliance owned by the same person without beingrecycled or reclaimed, unless the appliance is an MVAC

(Motor Vehicle Air Conditioner) like appliance.

Type of Appliance Manufactured

Before 11/15/93

Manufactured

After 11/15/93


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Before 11/15/93 After 11/15/93

HCFC-22 appliances or isolated

components of such appliances

normally containing less than 200 lbs.of refrigerant.

0 0

HCFC-22 appliances or isolated

components of such appliances

normally containing more than 200

lbs. of refrigerant.4 10

Other high pressure appliances orisolated component of such appliance

normally containing less than 200 lbs.

of refrigerant.4 10

Other high pressure appliances or

isolated component of such appliancenormally containing more than 200

lbs. of refrigerant.4 15

Very high pressure appliances

There are no questions on the exam

aboutVery high pressure appliances

0 0

After reaching the desired vacuum, wait a fewminutes to see if the system pressure rises


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minutes to see if the system pressure rises,indicating that there is still refrigerant in liquid

form or in the oil.

Appliances can be evacuated to atmosphericpressure (O psig) if leaks make evacuation tothe prescribed level unattainable.

The technician must isolate a parallel compressorsystem in order to recover refrigerant. Failureto isolate a parallel compressor system willcause an open equalization connection that will

prevent refrigerant recovery.

System-dependant recovery equipment cannot beused on appliances containing more than 15pounds of refrigerant.


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MAJORREPAIR

Under EPA regulations, a major repair means any

maintenance, service or repair involving the removal

of any or all of the following components: thecompressor, the condenser, the evaporator or an

auxiliary heat exchanger coil.


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REFRIGERANT TYPE

To determine the type of refrigerant used

read the nameplate.

FILTER / DRIER


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FILTER / DRIER

Filter driers will remove moisture from the refrigerant

in a system, but there is a limit to their capacity.

Some systems are equipped with a moisture indicatingsight glass. When the sight glass changes color, the

system contains excessive moisture and will need to be

evacuated.

The filter-drier should be replaced anytime a system is

opened for servicing.


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CRANKCASE HEATER

A crankcase heater is used to prevent

refrigerant from migrating to the oil during

periods of low ambient temperature.

Refrigerant in the oil will cause oil foaming

in the compressor at start-up.


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WARNING

A hermetic compressor's motor winding could

be damaged if energized when under a deep

vacuum.

NEVER energize a reciprocating compressor if

the discharge service valve is closed.


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132

LIQUID CHARGING

There is a risk of freezing during liquid charging of an

R-12 refrigeration system

Begin with vapor from a vacuum level to a pressure of

approximately 33 psig. Followed by a liquid chargethrough the liquid-line service valve. This is also the

proper method to charge a system that contains a large

quantity of refrigerant.


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133

ASHRAE

STANDARD 15

Requires a refrigerant sensor that will

sound an alarm and automatically start

a ventilation system in occupiedequipment rooms where refrigerant

from a leak will concentrate.

ASHRAESAFETYCLASSIFICATION


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FORREFRIGERANTS

CFC-12 CFC-11 HFC-134a

are all categorized as A-1

HIGHER

FLAMMABILITYA3 B3

LOWER

FLAMMABILITYA2 B2

NO FLAME

PROPAGATIONA1 B1

Lower

Toxicity

Higher

Toxicity


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135

Sample Type II Questions & Answers


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Sample ype Questions & nswe s

Here are ten sample Type II questions for you topractice with.

None of these are actual questions from the Type IIsection of the test.

They do not cover all of the subject material that youwill be tested on.

They do help you to practice multiple choice typequestions by reading carefully, reviewing what youhave read and just relaxing and doing your best.

S l T II Q #1


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Sample Type II Question #1

1. Type II Certification is required for

servicing, repairing or disposing of . . .

a. small appliances.

b. low pressure appliances.

c. high pressure appliances.

d. appliance installed since 1995.

S l T II Q i #2


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2. An indication of a potential leak on a high

pressure system is . . .

a. traces of oil.

b. excessive superheat.

c. low subcooling.


S l T II Q i #3


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3. Refrigerant leaks on comfort coolingsystems must be repaired if . . .

a. the system contains more than 50 lbs. ofrefrigerant.

b. the annual leak rate exceeds 15%.

c. the annual leak rate exceeds 35%.

d. Both A & B.



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p yp Q

4. Commercial & industrial process refrigeration

systems must be repaired if . . .a. the system contains more than 50 lbs. of

refrigerant.

b. the annual leak rate exceeds 15%.

c. the annual leak rate exceeds 35%.

d. Both a & c.



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p yp Q

5. Proper recovery equipment must be . . .

a. certified by an EPA approvedlaboratory.

b. Oilless.

c. HVAC approved.

d. able to be operated on dual voltages.



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p yp Q

6. Technicians working with R-134A must

use dedicated . . .

a. hoses & gauges.

b. recovery units.

c. vacuum pumps.




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p yp Q

7. Recovering refrigerant in the vapor phase

will minimize the loss of . . .

a. time.

b. certification.

c. oil.

d. nitrogen.



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p yp Q

After recovery, refrigerant may be . . .

a. sold to future customers.

b. reused in the same appliance.

c. Put into another appliance owned by the

same customer .

d. Either b or c.



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p yp Q

9. The R-22 in residential air conditioners

must be recovered to . . .

a. -4 inches of mercury.

b. 10 inches of mercury.

c. 15 inches of mercury.

d. 0 inches of mercury.



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p yp Q

10. System-dependent recovery equipment

cannot be used on systems . . .

a. ever!

b. containing more than 15 lbs. of refrigerant.

c. containing more than 5 lbs. of refrigerant.d. containing more than 50 lbs. of refrigerant.



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y y

Core click here:

Type I click here:

Type II (return) click here:




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148

TYPEIII

Technicians maintaining, servicing, repairing or

disposing of low-pressure appliances must be

certified as a Type III Technician or a UniversalTechnician.


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DESCRIPTION

A typical low-pressure centrifugal chiller operating

below atmospheric pressure uses a Shell style

evaporator with tubes of running water routed

through the evaporator.

The low pressure refrigerant within the shell

absorbs the heat carried by the water in the tubes.

The cold water within the tube system circulates throughout

the area where objectionable heat is to be removed


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the area where objectionable heat is to be removed.

The water then absorbs the heat from the area where it isnot wanted and transfers the heat to the refrigerant in the

shell evaporator.

The refrigerant travels through a normal vapor

compression circuit releasing its heat through a

condenser.

The system is protected from over-pressurization by a

rupture disc located at the evaporator.

A rupture disc differs from a relief valve in that when it

opens it remains open Most system rupture discs are set


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opens it remains open. Most system rupture discs are set

at 15 psig.

Low pressure equipment operates below atmospheric

pressure (in a vacuum).

The ambient air pressure surrounding gaskets & fittings is

greater than the internal pressure.

Because the internal pressure is less than the external airpressure, leaks in gaskets or fittings will cause air &

moisture to enter the system. For this reason it is

extremely important to maintain a tight system.

Low Pressure chillers are equipped with a

method of eliminating air and other non


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method of eliminating air and other non-

condensables that will leak into the system.

T

he PURGE UnitThe purge unit is located at the condenser. (Purge

units will be covered later in this section).


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LE AK DETECTION

Detecting a leak in a low pressure system is

unlike that of a high pressure appliance.

Refrigerant does not leak out of a charged low

pressure chiller air & moisture leaks in.

The systems internal pressure must be raised above the

ambient pressure before leak testing can be performed.


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ambient pressure before leak testing can be performed.

The best method of pressurizing the system is throughthe use ofControlled Hot Water (raising the

temperature of the circulating water within the tubes).

Heater blankets may also be used to aid in raising the

system pressure. When controlled hot water or heater

blankets are not feasible, use nitrogen to increase

pressure.

When pressurizing a system, do not exceed 10 psig.

Exceeding 10 psig can cause the rupture disc to fail.

L k t ti t b i li h d b


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Leak testing a water box is accomplished by

removing the water andplacing the leak detectorprobe through the drain valve.

To leak test a tube, use a hydrostatic tube test kit.

Controlled hot water can also be used to

pressurize a system for the purpose of opening thesystem for a non-major repair

MAJOR REPAIRS


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MAJORREPAIRS

The EPA defines a major repair as anymaintenance, service or repair involving the

removal of any or all of the following

components: the compressor, the condenser,

the evaporator or any auxiliary heat exchangercoil.


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EPA regulations require that all comfort cooling appliances (air

conditioners) containing more than 50 lbs. of refrigerant MUST

be repaired when the annual leak rate exceeds 15%.

EPA regulations require that all Commercial and Industrial

Process Refrigeration containing more than 50 lbs. of

refrigerant MUST be repaired when the annual leak rate

exceeds 35%.

CommercialRefrigeration includes appliances used in the

retail food and cold storage warehouse sectors, including


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retail food and cold storage warehouse sectors, including

equipment found in supermarkets, convenience stores,

restaurants and other food establishments, and equipment

used to store meat, produce, dairy products and other

perishable goods.

Industrial ProcessRefrigeration means complex

customized appliances used in the chemical,

pharmaceutical, petrochemical and manufacturingindustries, including industrial ice machines and ice rinks.

LOW-PRESSURE


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RECOVERYEQUIPMENTA recovery unit's high pressure cut-out is set for 10

psig when evacuating the refrigerant from a low-

pressure chiller and a rupture disc on a low-pressure recovery vessel relieves at 15 psig.

Most low-pressure recovery machines utilize a

water-cooled condenser that is connected to themunicipal water supply.

Recovery Techniques


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Refrigerant recovery from an R-11 or R123 system begins

with liquid removal and is followed by vapor recovery.

Water must be flowing through the tubes while refrigerant is

drained to prevent freezing. The recovery compressor and

condenser should also be operating.

Substantial vapor remains within the system even after

liquid is removed

An average 350 ton R-11 chiller after liquid recovery will

stillcontain approx. 100 lbs of refrigerant in vapor form. In an R-11 system, 10% of refrigerant can remain in the

system in vapor form even after liquid recovery.

Recovery Tips


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Recovery Tips

If a system is suspected of water tube leaks, thewater sides of the system should be drained priorto recovering the refrigerant.

When vacuum testing a system, if the absolutepressure rises from 1mm Hg to any point above2.5mm Hg, the system should be checked for leaks

(ASHRAEGuideline 3-1996)

System oil should be heated to 130F prior todraining to ensure the release of refrigerant fromthe oil.

Recharging Requirements


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RechargingRequirements

Initial charging must occur in the vapor phaseuntil the systems pressure has reached 16.9 hg

vacuum. This insures that water will not freezeand the refrigerant will not boil. R-11 at 32Fhasa saturation pressure of 18.1Hg.

The system is charged through the lowest accesspoint on the system, the evaporator charging valve

Recovery Requirements


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Recovery Requirements

Levels of evacuation for low-pressure appliances:

For Refrigeration Recovery & Recycling Equipment

manufactured or imported Before November 15th

, 1993:

25 inches Hg

For Refrigeration Recovery & Recycling Equipment

manufactured or imported on or After November 15th, 1993:

25 mm Hg absolute

Recovery Tips


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Recovery Tips

System pressure should be monitored after

evacuation for a few minutes to ensure the

maximum amount of refrigerant has been

removed. If pressure rises, recovery must be

repeated.

Systems that cannot attain or maintain stated

levels of evacuation should be evacuated to thehighest possible level prior to repair.

Refrigeration Pointers


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Refrigeration Pointers

Freezing water must be avoided. If necessary, usenitrogen to increase pressure to counteract freezingwhile evacuating a system.

Strong odors and contaminated oil are possibleindications of a compressor burn-out.

The purge unit operates with suction from the top ofthe condenser. It removes air, moisture and other non-condensables from the system and returns refrigerant at

the evaporator. If frequent purge operation occurs, orexcessive moisture is detected in the purge unit, one ofthe systems tubes may be leaking.

Rupture Disc


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Rupture Disc

Releases pressure in a low-pressure system when itexceeds 15 psig.

Protects the system from over-pressurization.

SAFETY


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Equipment rooms must be monitored for highrefrigerant levels, in which case an alarm must

sound, and a ventilation system must be

automatically activated.

-ASHRAE standard 15(for all ASHRAE refrigerant safety groups)

All refrigeration systems must be protected by a

pressure relief valve(s)

Never install relief valves in series

ASHRAESAFETYCLASSIFICATION

FORREFRIGERANTS


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HIGHERFLAMMABILITY

A3 B3

LOWER

FLAMMABILITYA2 B2

NO FLAME

PROPAGATIONA1 B1

Lower

Toxicity

Higher

Toxicity

CFC-12 CFC-11 HFC-134a are all categorized as A-1

R-123 (an HCFC) is categorized as B1


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169

Sample Type III Questions & Answers


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Here are ten sample Type III questions for you topractice with.

None of these are actual questions from the Type III

section of the test.

They do not cover all of the subject material that youwill be tested on.

They do help you to practice multiple choice type

questions by reading carefully, reviewing what youhave read and just relaxing and doing your best.

Sample Type III Question #1


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1. Type III Certification is required for . . .

a. high pressure systems

b. low pressure systems

c. medium pressure systems

d. ammonia-based systems



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2. Low-pressure systems operate . . .

a. without lubricants

b. in a vacuum

c. between 100 & 200 PSI

d. with HCFC-22



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3. Refrigerant recovery of R-11 starts . . .

a. with vapor recovery followed by liquid

recovery

b. with liquid recovery followed by vapor

recovery

c. with removal of all dryers and receivers

d. with removal of all refrigerant oil



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4. When evacuating refrigerant from a R-11

chiller . . .

a. circulate water through the tubes.

b. the compressor must be operated.

c. drain all water from the system.

d. disconnect the crankcase heater.



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5. If leaks in a R-11 system make evacuation

to the prescribed level unattainable, the . . .

a. system must be scrapped.

b. leaks must first be repaired.

c. system evacuation level should be aslow as possible.

d. jobsite must be reported to the EPA.


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7. The typical design burst pressure for a

rupture disc is . . .

a. 5 PSI.

b. 10 PSI.

c. 15 PSI.

d. 30 PSI.



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8. R-11 is rated as . . .

a. flammable in the presence of chlorine.

b. non-flammable with high toxicity.

c. non-flammable with low toxicity.

d. highly carcinogenic.



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9. All refrigeration systems must be protected by

a. crankcase heaters.

b. suction accumulators.

c. pressure relief valves.

d. heat sensitive limit controls.



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10.The standards for recovery units change for

units manufactured or imported after . . .

a. November 15, 1993.

b. November 15, 1992.

c. April 15, 1988.

d. April 15, 1995



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Core click here:

Type I click here:

Type II click here:

Type III(return) click here:

You are almost done! keep going!


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Correct!

Click here to return to the quiz. Then click

again to answer the next question.

Conclusion:


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When is the next exam date?

How do you register?

What can you bring with you to the exam?

What MUST you bring with you?

What else can you study?

R t ti ?

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